Building structure



July-14, 1936. B. .1. POLL'ARD BUILDING STRUCTURE Filed April 1, 1952INVENTOR. Bernard c/ Foilard ATTORN 25 Y? Patented July 14, 1936 UNI EDsrArEs PATENT OFFICE BUILDING; STRUCTURE Bernard J. Pollard, Detroit",Mich.

Application Apri-t l, 1932;. SerialiN-im 6025509 tially the sameco-efficient of. contraction and expansion whereby cracking of the:integral structure will. be substantiallyeliminated. In- 0971? rying.out this important object I. contemplate: utilizing 'cinders' of asi'ze:larger than those hitherto utilizedv for aggregate and: associatingtherewith for bonding? purposes a cinder mortar; In: this way a.substantially homogeneous: integral structure may be builtup whichwilllcontract and.

expand. more: or less. as an unit? with changing: temperature, therebyminimizing disintegration: by reason of cracking and subsequent seepageof. moisture.-

it further: obziject oithe: invention is to provide a wallpossessing-great. tensile strength. Such. a.

wall' is. particularly adaptedfori use inv conjunc tion with veneerwork: and; for garden: wall or' fencing purposes.

Yet another object ofzthe'invention is to provide a decorative:veneerr'wall. of; attractive and unusual appearance which may be:inexpensive 1y built and is; of a; durable nature:

Afurth'er improved featureof the invention resides in. a novel method ofpouringwalls: whereby the exterior faces ofi'the. aggregate: utilizedare left free. andv clear of thebonding element. In this way the:decorative f eatures; of the. aggregate areretained on the exteriorfaces oilv the wall structure while at the same:- time the wall. isbuilt in the most inexpensive and rapid fashion known in: the traderReferring now to the drawing wherein like numerals represent similarparts throughout the several figures,

Fig. 1 illustrates in perspective one form of my improved wall, 7

Fig. 2 illustrates a somewhat modified form,

Fig. 3 is a section through a wall during the process of pouring thesame, and

Fig. 4 is a section through one of the blocks.

Hitherto cinders have been utilized in building structures in variousways, primarily in the form of cinder blocks wherein aggregate ofrelatively small size is screened to maintain certain size limits. Suchblocks include a relatively large proportion of cement in relation tothe cinder aggregate utilized and are necessarily subject to sufficientexpansion and contraction with temperature changes to produce cracking.Ginder blocks are a substantial; improvement over concrete: constructioninsofar ascracking: is con cernedi.

In one form of wall I propose to utilize cin-- ders of relatively largesize; the sizebeing com-- 5 parable. to that of the ordinary buildingbrick; andbonding the same: together; in the same man:- ner as. brick.or stone: walls: are bonded, with cinder mortar;

In Figure; J; a wall: wherein the cinder or clinker aggregate Ill: has:been. laid individually, as. bricks would be laid, is' illustrated. Thebonding material l'2 is: mortar having: fine'cinder a gregate. for thepurpose. of providing. a. co-etficient. of expansion in the: mortar.substantially equal. to that of the large aggregate. used. The wall in:Figure L constitutes a veneer overlying a foundations wall Ht and; asillustrated at. t5; the: outer faces oi. the cinder. aggregate. form a.rough exterior: of rustic appearance", the decorative effeet ofi whichcanonly be appreciated: by viewing the actual: structure.

As is well! known, cinders or clinkers are: the non-combustible residueof solidi fiuek which. has been completely burned and, depending upongsthe type of: fuel utilized, the cinders are. of: varying colors andhues. Theacolorsifoundain such clinker or cinder are; fast and lastingand the peculiar physical characteristics of such; aggre' gaterender itpossible for the architect or builder to-produce: a. variety of eficts-aspot of color,

a. mass of color; a. rough castwall, or an. insert which cannotwell beproduced in any other Way..

Aniimportant characteristic of awall structure composed of the. materialheretofore: described resides in the: great" heat and sound. insulating"qualities derived from: the porous natiufez ofv the. clinker, as well asin the great tensile strength inherent in the wall by reason of the firmbond between the cinder mortar and the porous surfaces of the clinkers.The interior of the individual clinkers or cinders is full of voids thatare created by the burning of the fuel from which the clinker wasformed. These voids are full of mixed gas and air and constitute a. veryeffective insulator against heat and sound.

Another form in which the large cinder aggregate may be utilized isillustrated in Figure 2 wherein the aggregate has been molded intoblocks l6, which blocks are subsequently laid either as a wall proper oras a veneer against a background is. These blocks are preferably moldedindividually and one method of so molding them is to pour a certainamount of cinder mortar in the mold box, and subsequently fill the boxwith the cinder aggregate prior to hardening of the mortar. It isimportant that the aggregate utilized be of a greater depth than that ofthe poured mortar so that the exterior surfaces of the cinder aggregatewill project beyond the mortar to expose the decorative faces thereof.The lower left block in Figure 2 illustrates more clearly the internalstructure of the block and it will be apparent that the large cinderaggregate is utilized not only for the exterior face of the block butconstitutes the major body portion of the block body. The mortarutilized is only for the purpose of bonding the aggregate together andis not designed to form any substantial portion of the block proper.

The block illustrated in Figure 4 utilizes only a single layer ll ofclinker aggregate and is adapted primarily for veneer work where no loadneed be carried by the block.

By reason of the porosity of such aggregate walls may be pouredtherefrom with great success. An important feature of my improvedpouring operation resides in the manner whereby the exterior faces ofthe clinker are shielded from the bonding material or mortar which ispoured along with the aggregate to preserve the decorative effectthereof. In Figure 3 a wooden form comprising a base 20 and side walls22 and 24 is utilized for the pouring operation. The inner faces of theside walls 22 and 24 are lined with some yieldable substance 26 such asstraw prior to the pouring of the material. While straw constitutes oneavailable substance for this purpose, it has been found that mud servesthe purpose admirably and will crack when dried, falling off and leavingthe exposed aggregate surfaces. A large size cinder aggregate 28 andmortar are poured successively. A layer of mortar follows each layer ofaggregate, the preceding layer of mortar being forced down between thevoids around the under layer of aggregate as each succeeding layer ofaggregate is poured thereon. The outer faces of the aggregate will imbedthemselves in the soft yieldable lining 26 of the form walls and thislining will constitute a protective coating preventing the mortar fromflowing over the said exterior surfaces.

When the form is removed, after the mortar has set properly, the liningmaterial for the most part will be drawn away with the walls thereof andany portion which sticks to the exterior faces of the cinder aggregatemay be easily removed, leaving the decorative body of the aggregateprojecting. Such a wall possesses all of the attractive and desirablecharacteristics of a wall wherein the aggregate is laid individually byhand. The irregularity of the surface contour of the clinkers or cinderaggregate assists materially in providing a strong tensile bondtherebetween, such tensile bond being enhanced greatly by virtue also ofthe porosity of the aggregate. A durable interlocking assembly ofsubstantially homogeneous material results from either the pouringoperation, the block formation, or the individually laid clinker.

To secure further decorative effect a slight amount of coloring materialmay be utilized in the mortar without in any way adversely affecting thebond secured between the clinker aggregate, or a wash of color materialmay be applied to the exterior surface of the mortar following the bondlines around the outer surfaces of the clinker.

By reason of the porosity inherent in the clinker aggregate the use ofair vents in veneer walls for insulation purposes may be substantiallyeliminated. Furthermore, walls built in the manner hitherto describedremain intact over a long period of time without the possibility ofindividual clinkers falling out, as is almost invariably the case withwalls built up from cobblestones or other aggregate having a smoothsurface which will not permit as strong a bond as the porous aggregateherein utilize-d.

A very effective structure may be secured for veneer purposes byutilizing a fine graded clinker which produces somewhat the same effectas stucco or pebble-dash without risking the deterioration invariablycaused by the contraction and expansion of such stucco work.

While various other forms of structure embodying the principles of myinvention may readily be devised, I wish to be limited as to scope onlyby the appended claim.

I claim:

A decorative structural Wall possessing heat and sound insulativequalities comprising irregular cinder aggregate of a size comparable tothat of ordinary building brick bonded together throughout with cindermortar and constituting substantially over fifty per cent of the totalvolume of the wall, said cinder aggregate containing a multiplicity ofclosed and gas filled voids providing heat and sound insulatingqualities, said cinder mortar confined within the plane of the exteriorsurface of the wall so that the exterior surface of the cinder aggregateprojects beyond the mortar to expose the decorative surfaces thereof,said irregular exposed protruding portions of the large cinders beinguncovered and entirely free of cinder mortar and constitutingsubstantially over fifty per cent of the outer exposed surface of thewall.

BERNARD J. POLLARD.

